sorento motor

1Sorento

2Compativa

Modelos competidores(Diesel))

1,7081,8451,7481,7601,7951,730Altura (mm)

112/4,000160/3,800115/3,800120/4,000103/3,800145/4,000M.Potencia(Ps)

26.5/1,75038/2,00026.5/1,90025.5/2,40024/2,00033/2,000M.Par(kg-m)

1,950

2,820

1,870

4,720

2,874

DaewooRexton

1,7712,0551,8841,9751,957Peso (Kg)

2,5572,5452,7022,7502,710Entre ejes(mm)

2,0681,8751,8141,8601,865Anchura (mm)

4,3684,2804,6584,7104,567Longitud (mm)

1,9503,2002,1712,4762,497Capacidad(cc)

LandRoverFreelander

MitsubishiPajero

OpelFrontera

HyundaiTeracan

KiaSorento

Item/Modelo

3Especificaciones del motor

Cierra(ATDC)

Abre(BBDC)

Cierra(DPMS)

Abre(APMS)

Escape

Admisin

1-3-4-21-2-3-4-5+61-3-4-2Orden de encendido5210 2-Avance de encendido (BTDC)

8005070010080050Ralent (rpm)0,(HLA)0,(HLA)0,(HLA)Juego de vlvulas

1420.585443.5525660.5381211.58

Cruce devlvulas

10:110:117.7:1Relacin de compresin86.5x10093x85.891x96Dimetro X carrera (mm)

2,3613,4972,497Capacidad (cc)MPIMPIDirect InjectionTipo de inyeccin

20.2/300030/300033/2000Max. Par (kg-m/rpm)140/5500195/5500145/4000Max. Potencia (Ps/rpm)

DOHCDOHCDOHCSistema de vlvulasIN-LINE 4 CylinderV6IN-LINE 4 CylinderTipo

SIRIUS-(2.4 I4)

3.5(V6)

A 2.5 TCICRDI

Items / Modelo

4Vista del motor A 2.5 TCI (CRDI)

A 2.5 TCI CRDI

5Vista del motor 3.5 (V6)

Sigma() 3.5

6Vista del motor Sirius- (2.4)

Sirius- 2.4 (In-Line)

7Cambio

Cambio manual : M5UR1

Cambio automtico : 30-40LEI

8Sistema de inyeccin diesel

Motor diesel

9A-2.5 TCI CRDI

A-2.5 TCI

10A-2.5 TCI (CRDI)

Incrementada la potencia especfica y reducido el consumo- DOHC 4 vlvulas por cilindro

- Turbo con intercooler

- Electronic Diesel Control(EDC)

de Bosch con Common Rail

- Inyectores de alta precisin controlados electrnicamente

montados en el centro de la cmara de combustin

- Alta presin de inyeccin, aprox. 1,350 bar

Reducido las emisiones, ruidos y vibraciones- Inyeccin piloto antes de la principal

- Arboles contrarrotantes

- EGR con catalizador por oxidacin

- Soporte de rboles de levas y doble crter

11A-2.5 TCI (CDRI) Curvas del motor

33/2OOO rpm145/4OOO rpm

Prueba : JIS 82 NETMotor : D4CB(A2.5 TCI)

12Turbo - VGT

VGT (Turbo de Geometra Variable)

Nozzle VaneVacuum Actuator

Unison Ring

13A-2.5 TCI (CDRI) Presin del turbo

Presin del turbo a la salida del intercooler

14A-2.5 TCI (CDRI) Intercooler

Enfriamiento del aire de admisin

Intercooler

15A-2.5 TCI (CDRI) Temperatura del aire

Temperatura del aire a la salida del intercoolerO

u

t

l

e

t

T

e

m

p

.

Engine rpm

Outlet Temp.

16A-2.5 TCI(CRDI) Diagrama de sistema de ral comn

Diagrama del sistema CP3

M

KL

A

D

B

C

E

F

G H I

J

O

N

17A-2.5 TCI(CRDI) Diagrama del sistema de ral comn

Componentes- : Depsito- : Prefiltro- : Filtro de combustible- : Bomba de baja presin- : Bomba de alta presin- : Valvula de control- : Ral comn- : Vlvula limitadora- : Lnea de retorno- : Lnea de alta- : Lnea de baja- : Inyector

- : Sensor del rbol de levas -- : Sensor de flujo de aire- : Sensor de temperatura- A : Rel de calentadores

- B : ECM

- C : Sensor del cigeal

- D : Sensor de alta presin

- E : Turbo

- F : Vlvula de descarga

- G : Sensor del acelerador

- H : Interruptor de freno

- I : Interruptor del embrague

J : Interruptor A/C

- K : Conector de diag.

- L : Can Bus

- M : Cuadro

- N : Modulador de vaco

para la EGR

- O : Batera

18A-2.5 TCI(CRDI) - Limpieza

LimpiezaLa alta presin requerida en los sistemas de ral comn hacen necesario hacer losorificios de los inyectores mucho ms pequeos que los de un sistema convencional.

Por ello, la limpieza a la hora de trabajar con estos sistemas es fundamental e imprescindible.

Orificio del inyector

Cabello

19Sorento Engine Room

Bomba de altapresin

Vantilador del condensador

Intercooler

Vlvula EGRSensor de flujode aire

20A 2.5 TCI Vista frontal

Alternador

Tensor

Cadena de distribucin C

Bomba de altapresin

Embrague del ventilador

21A 2.5 TCI Embragur viscoso

Embrague del ventilador

22A 2.5 TCI Vista lateral

Calentadores

Sensor del cigeal

Enfriador de aceite

Filtro de aceite

Correa mltiple

Turbo

Compresordel A/C

Doble crter

Crter

23A 2.5 TCI Vista superior

Inyectores

Ral comn

Sensor de presin del ral

Vlvulalimitadora de

presin

24Caractersticas - Turbo

Turbo

- Turbo refrigerado por agua

- Vlvula de descarga

- Intercooler frontal

25Caractersticas Correa mltiple

Componentes

Correa mltiple

Bomba de direccin

Alternador

Rodillos

Bomba de agua

Compresordel A/C

Tensor

26Caractersticas Soporte de los rboles de levas

ComponentesArboles de levas

Soporte

El uso de soporte para los rboles de levasreduce el ruido y las vibraciones .

27Caractersticas Vlvulas

Componentes- 4 vlvulas por cilindro con ajuste hidrulico

Ajuste hidrulico

28Caractersticas Pistn y biela

Componentes- Pistones refrigerados por

aceite- Par de apriete de las tapas de biela :

apretar a 6.0kg-m aflojar Reapretar a 3.5kg-m apretar de 60~64 gradosPaso de aceite

Tornillos de biela

29Caractersticas NVH

Componentes

8 contrapesos

Arboles contrarrotantes

30Caractersticas - NVH

Componentes- Doble crter

Doble crter

31Caractersticas Oil Pump

Componentes- Bomba de aceite montada dentro del crter- Aceite usado : CE grade 10W30

Bomba de aceite

Doble crter

32Cadenas de distribucin

Componentes- Libres de mantenimiento- Compuesto por tres cadenas : A, B y C

CadenaCadena

TensorTensor

GuaGua

CadenaA

CadenaA

CadenaC

CadenaC

CadenaB

CadenaB

33Cadena A

Componentes- Mueve el pin del cigeal, la bomba de alta presin y el rbol

contrarrotante derecho

34Cadena B

Componentes- Mueve el pin del cigeal, la bomba de aceite y el rbol contrarrotante

izquierdo- Marcas alineadas en la instalacin inicial- Adecuado engrase de la cadena y la gua

Tensor

15 dientes

12 dientes13 dientes

35Cadena C

Componentes

5 dientes- Mueve la bomba de alta presin y los pines de los rboles de levas

Tensor automtico

Pin de la bomba de alta

presin

36Caution for Timing Chain

Reference- El reemplazamiento de las cadenas A y B no es posible con el motor montado, sin

embargo, la cadena C s.- La alineacin de las cadenas con los piones es fundamental, sobre todo en la

cadena C.- Hay tres tipos de piones para la bomba de alta presin. Cada vez que se cambie el

pin de la bomba, hay que medir la distancia entre el pin y la bomba y colocar el que corresponda.

C35.0-35.8Red

B33.4-34.2White

A34.2-35.0Blue

PinGrosor(mm)

Color

Bomba

Bloque

Pin

37A-2.5 TCI (CDRI)

Sistema de combustible

38Sistema de combustible

Common RailVlvula

limitadora

Inyector

Vlvula de controlde la presin

Lnea de alta presinSensor de presin

del rail

Bomba de altapresin

Lnea de retorno

Lnea de baja presin

39Sistema de combustible Lnea de baja presin

Depsito

Filtro de combustible- Decantador agua- calentador gasoil

Prefiltro(600)

Bomba desuccin

Inyector

Presin de succin(0.5-1bar)

Vlvula limitadora

Vlvula de control dela presin

Common rail

Presin(4-6bar)

Bomba de alta presin

Componentes

Sensor de presin del rail

40Lnea de baja presin - Componentes

- El depsito est situado debajo de la segunda fila de asientos- La capacidad es de 72- La vlvula de corte (situada bajo el filtro del aire) previene fugas de gasoil

del depsito al cnister en caso de emergencia

Componentes

Depsito

SalidaFiltro

Retorno

Conector del aforador

41Lnea de baja presin - Aforador

- Aforador : Detecta le cantidad de gasoil por mediode un potencimetro que manda la seal al cuadro

- Luz de reserva : Cuando el ptencimetro marca un ciertovalor durante 60 20 segundos, la luz de reservase enciende.

Rel de la luz de reserva

812365472Capacidad del

depsito()

110283232.51.518.5131ResistenciaValor()

VacoLuz de reserva on1/23/4LlenoPosicin

Valor de resistencia del aforador

42Lnea de baja presin Filtro de combustible

Componentes- El sistema de rail comn necesita un gasoil

mucho ms limpio que un sistema convencionalpor varias razones.

- El agua y los contaminantes slidos, sobre todoen invierno, dan lugar a desgaste, erosin,filtroobstruido, picaduras, prdida de presin yeventualmente falta de lubricacin de la bomba.

- Para reducir estos problemas, el Sorento montaun filtro Bosch con decantador de agua y calentador de gasoil incluidos.

- Componentes : Filtro INterruptor de temperatura del gasoil Sensor de agua Calentador del gasoil Purgador

43Lnea de baja presin Sistema de calentamiento

Descripcin- Previene que el gasoil se solidifique a

bajas temperaturas.

- Funcionamiento : on : por debajo de -5off : por encima de 3

IG

RelBateraCalentador

Interruptor de temperatura

Caja de fusibles

Diagrama

Interruptor de temperatura

Calentador

44Lnea de baja presin Bomba de aspiracin

45Sistema de combustible Lnea de alta presin

Depsito

Filtro de combustible

Prefiltro(600)

Bomba de succin

Inyector

Presin(0.5-1bar)

Vlvula limitadora

Vlvula de controlDe la presin

Common rail

presin(4-6bar)

Bomba de alta

Linea de alta presin

Sensor de presin del rail

46Lnea de alta presin Vlvula de control de presin

Vlvula de control Bomba de altaBomba de aspiracin

Componentes


Componentes

- Carga (4500rpm):Ciclo 35% Presin del rail1350bar

- Ralent (800rpm) :Ciclo 45% Presin del rail 270bar

49Lnea de alta preain Bomba de alta presin

Componentes

Bomba de altaVlvula de control de presinBomba de aspiracin

Salida de alta

Retorno de baja

Entrada de baja

50Lnea d alta presin Bomba de alta presin

Componentes

- Componentes principales : Eje principal Eje excntrico. Pistones Vlvula de entrada Vlvula de salida

Vlvula de entrada Vlvula de

salida

51Lnea de alta presin Rail comn

Componentes

Rail Entrada desde la bomba Sensor de presin del rail Vlvula limitadora de presin Tuberas de los inyectores

52Lnea de alta presin Vlvula limitadora de presin

Componentes

Vlvula mecnica.Abre cuando la presin en el rail sube a 1.750 bares

Conexin al rail Paso de combustible Pistn Muelle Retorno de combustible

53Lnea de alta presin Inyector

Componentes- Situado en el centro de la cmara de combustin,

inyecta el combustible en la cantidad y tiempoexacto determinado por la unidad de control.

Parte del solenoide

Parte mecnica

Parte de inyeccin

Corriente inicial de apertura : 80V/20A


Componentes Cerrado Abierto

Retorno de combustible Conector Solenoide entrada de combustible Bola Canal de descarga Canal de alimentacin Cmara de control Embolo Paso de combustible Aguja


Componentes :- Secuencia de la inyeccin :

A = Intensidad

B = Carrera en mm

C = Presin en alta

D = Tiempo de inyeccin

a = Coriiente al solenoide

b = Carrera de la vlvula

c1 = Presin en la cmara de control

c2 = Presin de alimentacin

d = Inyeccin


Control de la inyeccin :

18~20A 10~12A

Injector

50%

45%

1 Descarga del condensador

2 Apertura del inyector

3 Carga del condensador

4 Mantenimiento de la corriente

5 Carga del condensador

6 Corriente de mantenimiento

7 Corriente de mentenimiento

57Lnea de alta presin Inyector Descripcin :

- Inyeccin piloto :

1 = Inyeccin piloto 1a = Presin de la inyeccin con inyeccin piloto

2 = Inyeccin principal 2a = Presin de la inyeccin sin inyeccin piloto


Descripcin :- Montaje del inyector :

Entrada de combustible

- Par de apriete : 2.5~2.9kg-m

Arandela de sujeccin

- Par de apriete : 3.10.3kg-m

59EDC

Electronic Diesel Control

(EDC)

60EDC Entradas / Salidas

entradas salidas

1. Sensor de masa de aire

2. ECT Sensor

3. IAT Sensor

4. CKP Sensor

5. CMP Sensor

6. Rail Pressure Sensor

7. Acel. Pedal Sensor

8. Interruptores

- Freno

- Embrague

- A/C

9. Sensor vel. vehculo

1. Inyector

2. Vlvula control presin

3. Rels

- Principal

- Calentadores

- Ventilador

- Ventilador condensador

4. VAC modulador de EGR

5. Calentadores refrigerante

6. CAN

ECM

61EDC ECM

Descripcin : - Borrado de cdigos de avera :

Los cdigos de avera almacenados en la ECM slo pueden ser borrados usando

el Hi-Scan Pro.

- Funcin de identificacin :

Ya que el Sorento usa la misma ECM, ya sea con cambio manual o cambio

automtico, es necesario programar el tipo de cambio usado utilizando el

Hi-Scan Pro.

Sorento ECM conector

62EDC Emergencia

- Parada de emergencia

Por razones de seguridad, la ECM efecta una parada del motor cuando hay una

avera en los siguientes casos :

Inyectores Sensor del cigeal vlvula de control de presin Fugas de combustible

- Atencin : No se debe trabajar en el sistema de combustible hasta pasados 30

segundos despues de que el motor est parado.

63EDC Sensor de masa de aire con pelcula caliente

Componentes :- El principio de funcionamiento est basado en el enfriamiento de la pelcula

caliente, esto produce una variacin de la resistencia que la unidad traduce

en la cantidad de aire que entra. Este valor es usado por la ECM exclusivamente

para el funcionamiento de la EGR. El sensor de temperatura del aire de

admisin est integrado.

- Functions :

Control de la EGR Correccin del combustible en aceleracin y desaceleracin.

Sensor de aireECM

AFS Output (V)

Reference (V)

B+(12V)

IAT Output (V)

Ground

64EDC Sensor de masa de aire

- En caso de avera, las revoluciones del motor se limitan a 2250rpm

Y

Fuel Limit

General Error(Reference Volt> 4.7~5.1)C003

Signal above upper limit(Air mass>800kg/h)C002

Eng.Run

Y

Signal below lower limit(Air mass

65EDC Sensor de tem. del aire de admisin

Descripcin :[Characteristic curve]- El IAT est integrado en el sensor de masa de aire.

Usando una resistencia NTC, el sensor mide la

temperatura del aire de admisin.

Cuando hay una avera en el sensor, el valor de

temperatura alternativo es de 50.

Fuel Limit

(Malfunction set value : 50)

Signal above upper limit(Signal>4.97V)C002 IG OnY

Signal below lower limit(Signal

66EDC Sensor del pedal del acelerador

Descripcin :- El sensor del pedal de acelerador est situado en el pedal del acelerador y

mide la posicin del pedal para controlar la cantidad de inyeccin a travs de

la seal que llega a la ECM. El sensor est compuesto de dos potencimetros

APS1 y APS2. El APS 1 es el sensor principal y el APS 2 se usa para controlar

el funcionamiento correcto del APS1. El valor del sensor APS 2 es justo la mitad

que el valor del APS 1.

APS1 Reference

APS1 Signal

APS1 Ground

APS2 Reference

APS2 Signal

APS2 Ground

ECM


- Cuando hay un fallo del sensor las revoluciones del motor se limitan a 1250rpm

General error(Reference Volt>1.7~5.1)C003IG On

Plausibility error with brake signalC004

IG OnYY

Signal below lower limit(Signal 2.45V)C002

General error(Reference Volt>1.7~5.1)C003

Y

Fuel Limit

Plausibility error (APS 1 and APS 2)C004

Signal above upper limit(Air mass>4.9V)C002Y



- Ralent : - Carga total :

69EDC Sensor del cigeal (CKP)

Descripcin :- El sensor del cigeal (CKP) es del tipo inductivo. Al paso de los dientes de la

corona dentada (60 2) genera una corriente alterna que enva a la ECM, que traduce

la seal y calcula las revoluciones del motor y el PMS.

Shield Ground

ECM

Signal (+)

Signal (-)

70EDC Sensor del cigeal

- Si hay cdigo de avera, el motor se para y no vuelve a arrancar.

CrankshaftMechanicalTarget Wheel

ON = 0V

Output sensorElectrical signal

1 tooth = 6

Tolerance = +/-0.45 crankshaft

OFF =5V

Reference point of the target usedby EMS to synchronize the engine

Sensor motion direction

Air gap=10.5mm

5V Above4.7V

Below0.8V

ECM

ON1.8OFF4,2V

71EDC Sensor del rbol de levas (CMP)

Descripcin :- El sensor del rbol de levas (CMP) es del tipo Hall :El sensor del rbol de levas controla la posicin del rbol delevas enviando una seal

a la ECM, de esta manera, la ECM cual es el pistn que est en la carrera de

compresin, algo que slo con el sensor del cigeal es imposible determinar.

Ground

Sensor signal

ECM

72EDC Seal del CMP y del CKP

YCKP&CMP General error (Rationality check)C003

Fuel Limit

CKP Plausibility errorC004

CMP Signal above upper limitC002Eng. RunY

No STARTCMP signal below lower limit(No signal)C001

0340

MILOn

EGRoff

Fuel= 0

CCDTCCheck

Condition

SymptomsDetail Description

Code

- Si hay un fallo del sensor, el motor sigue funcionando, pero no vuelve a arrancar.

73EDC Sensor de presin del rail (RPS)

Descripcin :- El sensor de presin del rail (RPS) est ubicado en el rail:

El objetivo del sensor es medir la presin del rail en cada momento mandando una

seal en forma de voltaje a la ECM.

Signal

Reference

Ground

ECM

74EDC Sensor de presin del rail (RPS)- Si falla el sensor, el motor se para y no vuelve a arrancar.

Y

Fuel Limit

General Error(Reference Volt> 4.7~5.1)C003

Signal above upper limit(Signal>4.8V)C002 Eng.RunYYY


75EDC Rail Pressure Sensor(RPS)

* Pressure target value check(Negative deviation)C008

Y

Fuel Limit

* Pressure target value check (Positive deviation)C010

* Pressure lower limit by rpmC006Eng. RunYY

Maximum pressure exceed(pressure >1480bar)C005

1181

MILOn

EGRoff

Fuel= 0

CCDTCCheck

Condition


Code

- Pressure monitoring : only conduct more than 700 rpm condition

Pressure lower limit by rpm : 120bar / 800rpm, 180bar / 2000rpm, 230bar / 3000rpm, 270bar / 4000rpm

Pressure target value check : (RPS stuck, wiring problem)350bar / 800rpm, 300bar / 2000rpm, 250bar / 3000rpm

Pressure target value check : (fuel leakage, failure from feed pump or high pump)300bar / 800rpm, 250bar / 2000rpm

76EDC Sensor de tempetatura del refrigerante (WTS)

Components Descriptions :- El sensor est situado en la culata :

el sensor del tipo NTC mide la temperatura del refrigerante y manda una seal a

la ECM. La resistencia del sensor disminuye cuando la temperatura del

refrigerante aumenta.

La ECM utiliza la seal para calcular el avance de la inyeccin y adecuar las

revoluciones del motor. Tambin disminuye la cantidad de inyeccin cuando

el motor est a la temperatura de servicio.

Heat gauge unit

Ground

Signal

ECM

77EDC Sensor de temperatura del refrigerante (WTS)

[Characteristic curve]

- Si falla el sensor :

No funciona el A/C ni el precalentamiento delrefrigerante, el ventilador funciona constantemente.

Valor alternativo : despus del arranque : 80antes de arrancar : -20

IG. OnSignal below lower limit(Signal 4.9V)C002

MILOn

EGRoff

Fuel= 0

CCDTCCheck

Condition


Code

78EDC Interruptor del freno

Descripcin :Hay dos interruptores por razones de seguridad. Cuando el pedal de freno se pisa

el interruptor 1 se cierra, mientras que el 2 se abre.

A travs de estas seales contrarias, la ECM es capaz de controlar en todo momento

el estado del interruptor del freno.

Brake switch 1

Brake switch 2

ECM

79EDC Interruptor del freno

0703 IG On

Fuel Limit

Plausibility error (comparing switch 1& 2)C004

MILOn

EGRoff

Fuel= 0

CCDTCCheck

Condition


Code

80EDC Interruptor del embrague

Descripcin :- Slo se usa para cambio manual :

Reduce la emisin de humos al cambiar de marcha Control de crucero

Clutch Switch

ECM

0704 IG On

Fuel Limit

Plausibility error (No signal within 80km/h)C004

MILOn

EGRoff

Fuel= 0

CCDTCCheck

Condition


Code

81EDC Inyector

Descripcin :

Los inyectores montados en el Sorento tiene un sistema servo hidrulico y una

bobina. Corriente de apertura : 20A1A, corriente de mantenimiento : 12A1A

No.

1Ground

No.

4Ground

No.

3Ground

No.

2Ground

Power supply

Power supply

No.1 Injector No.4 Injector No.3 Injector No.2 Injector

82EDC Inyector

- Si fallan dos o ms inyectores el motor se para

automticamente. [Characteristic curve]

83EDC Inyector

Eng. RunYY

Low side Line short circuit(current>29.5~34A)High side line short circuit(current>28~36A)

C0180201020202030204

Fuel Limit

Line open circuitC019

MILOn

EGRoff

Fuel= 0

CCDTCCheck

Condition


Code

0201 : Injector No. 1 0202 : Injector No. 20203 : Injector No. 3 0204 : Injector No. 4

84EDC Sistema de calentadores

Descripcin :

El sistema de calentadores es responsable de un aranque perfecto

cuando el motor est fro y tambin acorta el periodo de

calentamiento, lo que reduce la emisin de gases.

CalentadoresRel de calentadores

85EDC Sistema de calentadores

- El tiempo de calentamiento depende de la temperatura y de las revoluciones.

- Hay tres modos en el sistema de calentadores ;

Precalentamiento :

0.73812Calentamiento(Sec.)

50 20 -10 -20Temp. refrigerante()

Durante el aranque : En caso de que el motor no arranque despus de tiempode precalentamiento, si en motor est por debajo de 60 los calentadoresse ponen en funcionamiento como max. durante 30 seg. Si antes de pasarlos 30 seg. el motor sube ms de 60, se paran los calentadores.

Post calentamiento : Si el motor no sube de 2500 rpm y la cantidad de inyeccines inferior a 75cc/min.

0102540Glow time (Sec.)

40 20 -10 -20Coolant Temp.()

86EDC Rel principal

Diagrama :

Main RelayBattery

ECM

87EDC Rel principal

IG. OnPlausibility Error(IG signal comparison)C0041616

Fuel Limit

MILOn

EGRoff

Fuel= 0

CCDTCCheck

Condition


Code

88EDC Calentadores del refrigerante

Tres calentadores

89EDC EGR Componentes :

Solenoide

VlvulaEGR

Main RelayECM

90EDC EGR - Diagrama :

Entrada de aire

Turbine

Col. escape

Col. admisin

MOTORInter-

Cooler

Bomba

de vaco

AFS signal

(EGR feed back control)

Feed back EGR

ECMTarget EGR

APS rpmControlled

Vac. PressureAdmisinVacoSealEscapeEGR Gas

Valve

91EDC EGR

IG. OnYShort circuit to Bat(+)C018

0403

Fuel Limit

Short circuit to GNDC019

MILOn

EGRoff

Fuel= 0

CCDTCCheck

Condition


Code

92Sigma() 3.5 Eng.

Engine

93Sigma() 3.5 Eng. - Contents

Contents

- Sigma() Engine Hardware- Sigma() Engine Management System

94Sigma() 3.5 Eng. Engine Concept

Sigma()3.5 Development concept

Lay-out- 3.5 Dohc FF (already installed in Carnival) FR Design

Performance- Low-middle range torque up --- VIS

Emission- Korean Domestic 2000, LEV, Euro -

NVH- HLA, Beam Bearing Cap, Engine Cover

Long Durability

95Sigma() 3.5 Eng. Engine Concept

Optimization of Aux. Drive Belt Lay-outDesignAccessory

Improved HC EM & Blow-by GasMoving

Added Vacuum Type VIS and Aerodynamic Port Design for Low-MiddlePerformance

Added MCC and Minimized Exhaust Gas Resistance for LEV

Intake & Exhaust

Cooling & Air-Vent Sys. Design for EngineInstall(5incline in fornt side)Cooling

Oil Level Stability of Up/Downhill at 35 Degree and Fast TurningLubrication

RemarkBL

-3.5 FRSys.

96Sigma() 3.5 Eng. Main component comparison Comparison

GQ3.5 BL3.5Part No. Part No.

Water Temp Sensor & Heat Gage Unit

39220-3802039220-38030

ELEC. KOREAINSI

Ignition Coil 27300-39050 27300-39800 DENSO PUNGSONG- Small different shape- Same performance- Integrated Power_Tr

Ignition Failure Sensor 27370-38000 Hyundai Autonet

Spark Plug 18817-11051(PFR5N-11)27410-37100(RC10PYPB4) WOOJ INSERIM

- Pt alloy, Gap: 1.0~1.1- Cu-Ni/Pt, Gap: 1.0~1.1

Air flow sensor 28100-3940028100-39450 BOSCH

BOSCH KOREA - Hot Film Type

Air Temp. Sensor Integrated in AFS -

Crank Angle Sensor (CAS) 39310-39010 39310-39800 VDO HALRA - Hall IC

Cam position Sensor(CPS) 39310-39110 39318-39800 VDO HALRA - Hall IC

ECU 39110-39600 39110-39420 KEFICO - GQ : PCU(ECU+TCU)- BL : ECU (separated TCU)

Throttle Body Assy 35100-39610 35100-39600 DEASONG - Small different shape

Throttle Position Sensor* incorporated in TH/B - Same Sp- with idle switch

Part Name3.5 ENG

MAKER REMARK

97Sigma() 3.5 Eng. Main component comparison

GQ3.5 BL3.5Part No. Part No.

Idle Speed Actuator* incorporated in TH/B - Same Sp- Stepping Motor

Fuel injector ass'y 35310-38010 KEFICO

Fuel pressure regulator 35301-39600 35301-39410 INZI- Same press.control (3.350.05Kgf/)- Different shape

Knock sensor 39320-35561 39510-39810 INZI- Same Spec (resonance-type : 11.0KHz)- Different L/Wire

MAP sensor 39300-3810039300-38200 KEFICO - 20~106.7KPa abs

O2 sensor (Bank1-Up) 39210-39800 39210-39820 WOOJIN - FLO Type (+ Heated type)- Different L/Wire

O2 sensor (Bank1-Down) 39210-39650 39210-39550 WOOJIN - Heated type- Different L/Wire O2 sensor (Bank2-Up) 39210-39600 39210-39820 WOOJIN - FLO Type (+ Heated type)- Different L/Wire O2 sensor (Bank2-Down) 39210-39025 39210-39500 WOOJIN - Heated type- Different L/Wire Purge solenoid valve 39460-38650 KEFICO - 60L

Case assy catalyst(MCC) 28530-39675(LH)28530-39685(RH) 28530-39410

Converter assy catalyst(UCC) 28950-39671 28950-38610

Part Name3.5 ENG

MAKER REMARK

98Sigma() 3.5 Eng. Main component

Throttle Body

Water-In

Water-

1) TPS (Throttle Position Sensor)- With Idle Switch

2) Idle Speed Control Motor- Stepping Motor- Control Range ( 0 ~ 120 Step )- Initial Position : 80 Step- After IG-Key Off,

Stop-position is initialized by ECU during power latch time.

3) Thermo. WAX- Operating according to water

temp.- Closed about 60 (water t

Outemp)


Ignition coil

- Integrated Power_TR ( IGNITOR )

- 2- Cyl. Simultaneous Ignition


ECMPulse

Generator

VBIgnition Failure Sensor

Comparator

G

Tachometer

IGf

IB

G

Coil (Power TR included)

IG+ Coil #1 Coil #2,3

IG Coil Primary Circuit Wave form

Ignition Failure Sensor Output

Ignition failure sensor

101Sigma() 3.5 Eng. General Description

Sigma() Engine- GeneralThe Delta engine is a compact V6 DOHC engine, light in weight due to the use of aluminum engine parts with high torque output in low and medium speeds. This engine incorporates only one timing belt .This has resulted in a reduction of noise and increase in serviceability.The Sigma engine is designed and manufactured by Hyundai Motor Company.

Items Sigma 3.5L Items Sigma 3.5L

Displacement(cc) 3,497 Injector Type 4Hole 2 Spray

Bore X Stroke(mm) 93 X 85.8 Injection Timing BTDC17.5Compression Ratio 10:1 Spark Plug PFR6.1-11

Firing Order 1-2-3-4-5-6 Spark Plug Gap(mm) 1.0mm

Basic IG. Timing( ) BTDC10 2 Oxygen Sensor ZrO2Idle RPM 700 100 Coolant Control Inlet Control

HLA End Pivot Type Air Flow Sensor Hot Film

Fuel Pres.(Kgf/) 3.33 ~ 3.35 EMS Melco

102Sigma() 3.5 Eng. Comparison with GQ

NoYesEGR

DOHC 4 ValveValve System Type

FRFFEngine Instl.

NAAspirationVacuumElectronicVis Type

209.8193.6Eng. Weight (DRY, Kg)

608658780746758733Eng. Size (LxWxH, mm)

1-2-3-4-5-6Firing Order

10.0Compression Ratio93.0 x 85.8BS (mm)3,497Dis. (CC)G6CUEngine Code

RemarkBL

-3.5 FRGQ

-3.5 FFItem

103Sigma() 3.5 Eng. Sigma()3.5-Engine Hardware

- The sorento is equipped with the Sigma 3.5 Liter Engine with 195 hp @ 5500rpm

and torque30 @ 3500rpm. The intake manifold features a variable intake system

which extends the torque curve by selecting designated intake runners to

improve performance. The block is made of cast iron. The

cylinder heads and upper oil pan are

aluminum. Hydraulic Lash Adjusters(HLA)

eliminate the need for valve lash

adjustments. There are three drive belts

on the Sigma 3.5 enginewith mechanical tensioners. The timing

belt turns all four cam sprockets with an

hydraulic timing belt tensioner.

104

0

50

100

150

200

250

1000 2000 3000 4000 5000 6000 7000Engine Speed [rpm]

P

o

w

e

r

[

p

s

]

.

18.0

22.0

26.0

30.0

34.0

T

o

r

q

u

e

[

K

g

.

m

]

.

BL GQ

BLXG

SYSTEM MAX. POWER( Ps/ r pm)MAX. TORQUE( Kg. m/ r pm)

195197

30. 029. 8

Sigma() 3.5 Eng.- Performance Curve(WOT) Performance Curve

105Sigma() 3.5 Eng. Engine Feature

Section View

- End Pivot Type HLA

- Dry type liner

- Steel Cylinder block

- AL material Upper oil pan

106Sigma() 3.5 Eng. Cooling System Cooling System

WATER PASSAGE

WATER OUTLET PIPE

W/OUTLET FITT'G THERMOSTAT HOUS'G

FROM HEATER

TO HEATER

FROM TH/BODY

TO TH/BODY

BYPASS FITT'G, RH

FROM RADIATOR TO RADIATOR

107

BL -3.5 FRGQ -3.5 FF

Sigma() 3.5 Eng. Intake System Intake System

108Sigma() 3.5 Eng. Drive Belt Drive Belt

BL/HP-3.5 FR

GQ-3.5 FF

-Three mechanical drive belt tension adjuster

109Sigma() 3.5 Eng. Engine Feature Timing Belt

- Hydraulic auto timing belt tensioner :

One cogged-tooth timing belt, that turns all four camshafts and the water pump.

110Sigma() 3.5 Eng. Engine Feature Cylinder Block

-Torque - Angle Method

Connecting Rod Cap(33~37Nm+90~94)-Torque tightening

Main bearing Cab bolts(70~80Nm)

111Sigma() 3.5 Eng. Engine Feature Cylinder Head

- Torque Tightening

Cylinder head bolts(105~115Nm)

- Hydraulic Lash Adjuster

End Pivot type HLA

Air bleeding method

112Sigma() 3.5 Eng. Ignition Timing Check Checking condition

- Normal Operating Engine Temperature(80~95).- No electrical load

- Neutral of Transaxle

- No operation of Steering wheel

Ground the No.3 pin(Ignition timing checking terminal) of DLT. Check the timing on crankshaft pulley with timing light.

1314151617181920

56789101112

34 12

113Sigma() 3.5 Eng. Idle Speed Adjustment Checking condition

- Normal Operating Engine Temperature(80~95).- No electrical load

- Neutral of Transaxle

- No operation of Steering wheel

Connect Hi-scan Pro to DLC( L-line Grounded) Ground the Ignition timing check terminal.

(To make engine stable, Ignition timing is controlled. ECM goes into Idle speed

adjusting mode)

Check idle RPM(700100rpm). If beyond the specification, adjust it through Idlespeed adjust screw.

Idle Speed Adjust Screw

114Sigma() 3.5 Eng. Fuel Filter

Location

Fuel Pump Module Fuel Filter

Recommended replacement intervals : 100,000 mile / 10Years

115Sigma() 3.5 Eng. EMS

Sigma()-engineEngine Management System

116Sigma() 3.5 Eng. Contents

Contents- System Configuration

- System Description

- ECM Input/Output

- OBD2 Functions

- Diagnostic Trouble Code

- ECM Wiring circuit

117Sigma() 3.5 Eng. System Configuration

118Sigma() 3.5 Eng. System Configuration General descriptions :

- The Sorento utilizes a Mitsubishi Electronics Company Engine Management System

(MELCO). The MELCO system features a single 32 bit Powertrain Control Module

(PCM) to control engine management as well as all automatic transaxle functions.

Serial communication is used to transmit data between the engine and transaxle

sections of the PCM. A sequential Multiport Fuel Injection system (SFI) is

incorporated, along with a distributorless ignition system.

- The ignition system of Sorento Sigma 3.5 engine is very similar to previous ignition systems used on Kia vehicles since 1998 with the exception of having an

additional coil for the 2 extra cylinders and and ignition failure sensor.

- Engine management system monitoring functions are conducted in compliance

with OBD- regulations. An EGR system is not employed in the Sorento.

119Sigma() 3.5 Eng. System Description System Description

Engine V6 3.5L DOHC

Emission Standard LEV (0.130 NMOG)

Evaporative System New EVAP/ ORVR

PCM MELCO

Microprocessor MH8305F(32bit)Frequency 32 MHz

Memory Size 512Kbyte

Catalyst MCC Monitoring

O2 sensor Yes

Misfire Yes

Fuel System Yes

Evap System 0.02in Leakage Monitoring

Thermostat Yes

MonitoringFunctions

Comprehensive Component Yes

MCC = Manifold Catalytic Converter

120Sigma() 3.5 Eng. rpm by Load rpm by load

BL3.5 NASVEHICLE

D RANGERPM

A/CONOFF 750 100

P,N RANGERPM

A/CONOFF 800 100

A/CONON 900 100

A/CONON 750 100

OVERRUNF/CUT RPM

P/N 4000

VEHICLE

IGNITION TIMMING BTDC 10 2

D 6198

121Sigma() 3.5 Eng. ECM Input/Output ECM Input/Output

Ignition

Injector

Idle Speed Cont. Motor

Main Relay Control

Fuel Pump Control

Cooling Fan Control

Diagnosis(OBD)

Input Output

Oxygen Sensor(Bank1, Sensor1)




Air Flow Sensor

Air Temp. Sensor

T.P.S.

C.M.P

C.K.P.

W.T.S

Manifold Differential Press. Sensor

Knock Sensor

Fuel Level Sensor

Fuel Tank Press. Sensor

Fuel Temp. Sensor

Ignition Detect Signal

Vehicle Speed Sensor

Power Steering Sensor

Ignition Switch

Battery Voltage

ECM

122Sigma() 3.5 Eng. ECM Input/Output Mass Air Flow Sensor(MAF)

The air flow sensor installed between the air cleaner assembly and the throttle body assembly integrates Intake Air Temperature Sensor. Air flow sensing part consists of the heater device for keeping the constant relative temperature difference and the sensor device for measuring the air flow rate, and detect the balance of heat loss on hot film as circuit current increment. The ECM can calculate the mass air flow rate to engine, and this is the most basic and important value for engine control in injection duration and ignition timing calculation.

LocationElectric Circuit Sensor Signal

1: Air Temp. Signal

2: Vb

3: GND

4: Vref

5: Air Flow Signal

-HFM5

123Sigma() 3.5 Eng. ECM Input/Output Throttle Position Sensor(TPS)

This is a rotary potentiometer having idle switch mounted on throttle body assembly.

This sensor provides throttle angle information to the ECM to be used for the detection of engine status such as idle, part load, full throttle condition and anti-jerk condition and acceleration fuel enrichment correction.


TPS & Idle S/W

1: GND

2: Idle Sig.

3: TPS Sig.

4: Vref

124Sigma() 3.5 Eng. ECM Input/Output Throttle Position Sensor(TPS)

- Sensor Signal

[ At idle fuel cut ] [ At idle running ]

125Sigma() 3.5 Eng. ECM Input/Output

Engine Coolant Temperature Sensor (ECT)The engine coolant temperature sensor integrated heat gauge is installed in the thermostat housing. This sensor having gold coated terminals provides information of coolant temperature to the ECM for controlling ;- Injection time and ignition timing during cranking & warm-up & hot condition - ISC Motor to keep nominal idle engine speed- Cooling & condenser fan etc.


WTS1: GND2: Heat gauge

3: WTS Sig.


Heated Oxygen Sensors (HO2S)There are four O2 sensors in a vehicle, two of them are installed in the upstream and the others are installed downstream of each bank of manifold catalyst.

The O2 sensors is consists of Zirconia type sensing element and heater. The sensing element produces voltage according to the richness of exhaust gas, and this voltage to reference in ECM reflect lean or rich status.

For each bank(1/2), ECM can control the fuel injection rate separately with the feedback of each front O2 sensor signals, and the desired air/fuel ratio which provide the best conversion efficiency is achieved.

The rear O2 sensors also inform ECM of lean or rich status of exhaust gas existing the closed-coupled catalyst.

The rear O2 sensor signals are used not only for the richness correction to control NOxemission effectively but for the determination of catalyst deterioration factor to monitor the catalyst converter.

And, the O2 sensor tip temperature is controlled to 750deg.C to get reliable sensor signal output by already programed O2 heater control function.


Heated Oxygen Sensors (HO2S)


HO2S Front

HO2S Rear

FR. Sensor, RE. Sensor

1: Sensor Sig.

2: Sensor GND

3: Heater Sig.

4: Vb

FR. Sensor Heater

128Sigma() 3.5 Eng. ECM Input/Output Crankshaft Position Sensor (CKP)

The crankshaft position sensor detects and counts the tooth on teeth target wheel(3) and provides ECM with the information on the current position of crank angle and cylinder, and also the duration of each tooth and segment. So injection and ignition could be activated exactly in desired crank angle and current engine speed could be calculated also. The Sigma 3.5 engine will not run if CKP sensor circuit failure conditions exist. The CKP is located adjacent to the crankshaft pulley (similar to 2.4 Optima).

LocationElectric Circuit

1: GND.

2: Sensor Sig.

3: Vb

-Hall effect type sensor

129Sigma() 3.5 Eng. ECM Input/Output Crankshaft Position Sensor (CKP)

Sensor Signal Synchronization with CMP

No.1 Cylinder TDC when both signals are at high.

130Sigma() 3.5 Eng. ECM Input/Output Camshaft Position Sensor (CMP)

The Hall effect camshaft position sensor detects the teeth target wheel(Irregular four teeth) and provides ECM with the information on the current position of piston and cylinder, and also the duration of each tooth and segment. So injection and ignition could be activated exactly in desired TDC of each cylinder. The CMP is installed near the exhaust camshaft sprocket on the left cylinder bank. The target wheel is on the exhaust camshaft, behind the sprocket.


CMP

1: GND.

2: Sensor Sig.

3: Vb

-Hall effect type sensor

131Sigma() 3.5 Eng. ECM Input/Output Knock Sensor

The knock sensor is installed to detect knock occurrence of each individual cylinders. The knock sensor signal is processed with filtering, signal noise level calculation and final decision of knock by comparing the noise level with calculated noise level threshold.

When knock is detected, ignition timings of corresponding cylinder are retarded by defined value, different engine operating conditions, and advanced again with delay and increment slop.

Location Sensor SignalElectric Circuit

1: Sensor Sig.

2: Shield GND.

-Piezo type sensor

At idle


Idle Speed Control Motor (ISC)Step Motor is installed to control the proper intake air amount to keep nominal idle engine speed and to avoid uncompleted combustion in closed throttle condition.The ISC Motor opening value is concluded by Engine load(A/C, Fans, Drive, ....), Altitude etc.ECM sends a signal to each coils of step motor in series to open or close the by-pass passage of throttle body. The idle speed actuator has four coils.

Electric Circuit Location

ISC STM

SAS Idle Speed Adjust Screw(SAS)

1: Control Sig. A

2: Vb.

3: Control Sig. B

4: Control Sig. C

5: Vb

6: Control Sig. D

-Coil type

FIAV(Fast Idle Air Valve) for cold

condition


Idle Speed Control Motor (ISC)Output Characteristic

Details

Operation Order

Valve Closing

Valve Opening

Activation Order

Valve Moving

A & B at the moment A/C Off On C & D


The six fuel injectors are sequentially activated by the PCM using ground controlled circuits. Each injector has four individual spray ports. The pulse signal from ECM actuates injector coil to open, thus inject a defined amount of fuel. The start and end of injection is controlled by ECM according to engine operating conditions.

Fuel Injectors


1: Control Sig.

2: Vb.

-Coil type


Fuel InjectorsOutput Characteristic

#1, #2 Cylinder Injection

at idle

#1, #2 Cylinder Injection

at starting

CKP

CMP

#3 Injection

#4 Injection

CKP

CMP

#1 Injection

#2 Injection

136Sigma() 3.5 Eng. ECM Input/Output Purge Control Solenoid Valve

20Hz pulse duty signal is sent from ECM to purge accumulated fuel in the canister charcoal. The Purge control valve is open or closed when OBD-II leakage monitoring is performed. The pulse duty to purge the canister is calculated according to engine operating condition(Engine speed, Mass air flow)

Flow rate

Electric Circuit LocationPressure difference

1: Control Sig.

2: Vb.

-Coil type

137Sigma() 3.5 Eng. ECM Input/Output Fuel Tank Pressure Sensor (FTPS)

This sensor,installed on the fuel tank, measures the pressure of fuel tank to detect leakage or malfunction of related component during the leakage monitoring of evaporative emission control system.

Sensor Characteristic & Signal

Electric Circuit

1: Sensor Sig.

3: Vref.

4: Sensor GND.

-Resistance type with Diaphram

2.5kpa

0

-2.5kpa

0.7V 2.5V 4.5V

Location

At the moment IG. Off On

138Sigma() 3.5 Eng. ECM Input/Output Fuel Level Sensor (FLS), Fuel Temperature Sensor (FTS) For engine management purposes, the Fuel Level Sensor(FLS) is also used as a supplementary device to assist with evaporative monitoring. The Fuel Temperature Sensor (FTS) is also incorporated for this purpose.

Location Sensor Signal

FLS at IG. Off On

FTS at IG. Off OnFuel Temp. Sensor Fuel Level Sensor

139Sigma() 3.5 Eng. ECM Input/Output Canister Close Solenoid Valve (CCV) NA only

The Canister Close Solenoid Valve (CCV) is normally open ; the ECM closes the valve to seal the evaporative emissions system for OBD-II leakage monitoring purposes. The CCV is located on the evap canister.


1: Control Sig.

2: Vb.

-Coil type


Manifold Absolute Pressure Sensor (MAP)

This sensor is installed at intake surge tank to adapt fuel system for the altitude of vehicle(by detecting atmosphere pressure).

Electric Circuit Location Sensor Signal

MAP Sensor

1: Sig.

2: Vref.

4: GND

-Piezo type sensor

At idle Acceleration

141Sigma() 3.5 Eng. ECM Input/Output Ignition Failure Sensor

The ignition failure sensor is employed for the purposes of detecting ignition systemMalfunctions. The three ignition coil primary circuits are connected through the ignitionfailure sensor. The ECM monitors the sensor output signal to determine if a failure condition exists. (The tachometer is also supplied with the ignition detect signal.)


IFS

1: Body GND.

2: Vref.

3: Vb Output

4: Vb Input

-IC type sensor


Ignition Failure Sensor

CKP

CMP

IG. #1

IG. #2

CKP

CMP

IG. #3

IG. Fail. sensor

The signal from IG. Failure Sensor is a kind of monitoring signal for the activation of each primary IG. Coil.

When each primary coil signal falls, the signal of IG. Failure Sensor rises.

ECM can monitor the primary IG. Coil signal at ECM outside with this signal and compares this signal with the each primary IG. Coil signal of ECM inside.

The frequency of both signal should be same. If there are any difference, ECM regards it misfire for the cylinder.

143Sigma() 3.5 Eng. ECM Input/Output Ignition CoilThere are three ignition coils-#1/#4, #2/#5 and #3/#6. Each ignition coil is integrated its own power transistor.

Electric Circuit Location Signal

1: Vb.

2: Body GND

3: Signal

-IG. Coil integrated TR

IG.#1 & CMP

144Sigma() 3.5 Eng. ECM Input/Output Variable Intake ManifoldLow to medium speed torque is boosted through the use of a Variable Intake Manifold. Intake manifold path is variable through the operation of VI vacumn according to the engine RPM. (3500rpm, on and off type)

Flow Location

V.I Sol. Valve

145Sigma() 3.5 Eng. ECM Input/Output Main RelayThe voltage after main relay is used to supply power to the sensors and actuators.ECM controls the Main Relay and its remains ON at Key off in order to store the adaptation values and fault status to the memory.


A: Control Sig.

B,C: Output Vb.

E,D: Input Vb

-Coil type

Output Characteristic

IG. KEY ON

M/RELAY ON

Around 10 sec

IG. KEY OFF

M/RELAY OFF

146Sigma() 3.5 Eng. OBD2 Functions

The signal from the O2 sensor upstream from the monitored catalyst and the associated monitoringoxygen sensor downstream from the catalyst are used to estimate the Oxygen storage capability:

If a catalyst has good conversion properties, the oxygen fluctuations upstream from the catalyst, generated by the lambda controller, are smoothed by the Oxygen storage capacity of the catalyst.

If the conversion provided by the catalyst is low due to ageing, poisoning or misfiring, then the fluctuations upstream from the catalyst exist also downstream from the catalyst.

Calculate a frequency ratio of output signals from the front and rear oxygen sensors according to the following equation.

Rf= Frequency of Rear Oxygen / Frequency of Front Oxygen

if Rf > R0(Threshold value), determine the catalyst malfunction.

Catalyst Efficiency Monitoring

147Sigma() 3.5 Eng. OBD2 Functions Misfire Monitoring

Misfire induces a decrease of the engine speed, therefore a variation in the segment period. The misfiring detection is based on the observation of this variation of segment period.As a result, ECM monitor the fluctuation of crank angular acceleration. If the crank angular acceleration is out of specification, ECM determines misfire on engine.

Main causes of misfiring: -injector shut-off-fuel pressure problems-fuel combustion problems-ignition cut-off

Misfire fade-out conditions:Min. engine rpm Max. engine rpm(6500)Min. engine load(0)Max. air mass gradientMax throttle gradientMax. ignition angle gradientAircon compressor activationCylinder shut-offRough road detectionCrankshaft oscilation.Shift changeSudden deceleration

Carb. A error:Check recurrence: 200CKP revolution Target: to avoid cataylist damage

Carb. B error:Check recurrence: 1000CKP revolutionEmission decrease

148Sigma() 3.5 Eng. OBD2 Functions O2 Sensor MonitoringThe fluctuation of O2 signal characteristics is significant to perform properly lambda feedback control. And, too slow sensing response of O2 signal can cause the increment of exhaust emission.

- Response time monitoringDetect the response time (TLR, TRL) of oxygen sensor output signals when air-fuel ratio is changed intentionally from lean to rich (TLR) or rich to lean (TRL) under the hot steady state condition.If TLR T1 or TRL T2 (T1, T2 : threshold value), determine the oxygen sensor malfunction.

149Sigma() 3.5 Eng. OBD2 Functions

A/F feedback compensation value (A/F learning value and Integral value of A/F feedback) is monitored. Injection time (T) is conceptually defined as follows ;

T = TB (KLRN + KI + 1.0) TB : Base injection timeKI is determined to achieve A/F ratio stoichiometric for short-term trim and KLRN for long-term trim.If KLRN K0 and KI K1 or KLRN K2 and KI K3(K0, K1, K2, K3 : threshold value),determine the fuel system malfunction.

Fuel System Monitoring

150Sigma() 3.5 Eng. OBD2 Functions Evaporative System Monitoring

At driving condition, the fuel tank pressure gradient and the duration to reach to certain tank pressure are monitored after vacuuming the evaporative system to use the throttle body vacuum through the purge solenoid valve and canister close valve. If the evaporative system has a small leakage such as 1mm leakage hole, the pressure gradient will be above a certain threshold map value which consists of P, T. At idle condition, if the evaporative system has a small leakage such as 0.5mm leakage hole, the pressure gradient will be above a certain threshold map value which consists of fuel temperature (FTMP), fuel level(FLVL).

-P Threshold map value (P, T) or, Threshold map value (FTMP, FLVL)where, P = (PREAL - P3) - (P2 - P1), T = T(P2') - T(P2)

-P2REAL > Threshold value

151Sigma() 3.5 Eng. OBD2 Functions Thermostat Monitoring

Engine coolant temperature from the sensor voltage is monitored. For thermostat monitoring, three Malfunction criteria (TWTFL_H, TWTFL_M, TWTFL_L) according to intake air flow are reduced per 500msec. Malfunction decision is performed when the counter of malfunction criteria is zero in the case of the engine coolant temperature is over thermostat regulating temperature.

Malfunction ConditionCoolant temperature at start : 5 60Coolant temperature at start - Intake air temperature at start < 10Intake air temperature at start - Intake air temperature < 5The integrated time of low air flow(TWOAFS) 200secThe integrated time of high air flow(TWOAFS_H) 100sec

Malfunction CriteriaThe counter of malfunction criteria(TWTFL_H, TWTFL_M, TWTFL_L) is changed.intake average air flow(Qave).Qave > 19.2g/sec TWTFL_H19.2g/sec > Qave > 11.52 g/sec TWTFL_MQave 11.52g/sec TWTFL_L

152Sigma() 3.5 Eng. Diagnostic Trouble Code

COMPONENTSYSTEM

FAULTCODE

MONITOR STRATEGYDESCRIPTION

MALFUNCTIONCRITERIA

THRESHOLDVALUE

SECONDARYPARAMETERS

ENABLECONDITIONS

TIMEREQUIRED

MILILLUM.

Closed loop Load value 25% ~ 70%

Engine speed < 2500rpmIdle switch off

Catalyst(Bank 1) P0421

Frequency ratio (Rf) of frontand rear oxygen sensor used.

Bank 1

FTP emission > 1.75 *emission standard > 0.801

Vehicle speed > 15KPH

150seconce perdrivingcycle

2 Drivingcycles

Closed loop Load value 25% ~ 70%

Engine speed < 2500rpmIdle switch off

Catalyst(Bank 2) P0431

Frequency ratio (Rf) of frontand rear oxygen sensor used.

Bank 2

FTP emission > 1.75 *emission standard > 0.801

Vehicle speed > 15KPH


2 Drivingcycles

P0300(Multi)P0301(#1 Cyl)P0302(#2 Cyl)

Engine speed 500~6250rpm

P0303(#3 Cyl)

FTP emission > 1.5 *emission standard > 2.2%

Load value 11% ~ 100%

1000revs.Continuous

P0304(#4 Cyl) No running on rough roadP0305(#5 Cyl) No shift change

Misfire

P0306(#6 Cyl)

Fluctuation of crank angularacceleration is monitored

Catalyst temp. > 950? > 5 ~ 20%within 200revs.No sudden deceleration

200 revs.Continuous

2 Drivingcycles

Surge voltage is monitored Surge voltage, Vps < Vb + 2V Battery voltage 10VFTPS voltage 1.0 V ~ 3.5V

Canister closevalve P0446 Clogging is monitored Preal < -200mmAq

Purge Duty 20%Continuous 2 Drivingcycles


Idle switch onFuel temp. < 45?P0456 0.02inch leakage of evap.System is monitored

Thresholdvalue(P,

FTMP, FLVL) Vehicle speed < 10KPH


Engine speed > 1500rpmLoad value 25 ~ 70%P0442 0.04inch leakage of evap.System is monitored

P = (Preal-P3)-(P2-P1)

Thresholdvalue(P, T)

Engine coolant > 60?Intake air temp. < 70?

P/S pressure s/w off

Evap. Purgesystem

P0455 Big leakage(fuel cap missing)

P2realbetween detecting P2

and detecting P3> -180mmAq

Vehicle speed 30KPH

2 Drivingcycles

P0441 Evap. Pressure is monitored Preal < -157mmAq

50sec once per

drivingcycle

Purge sol.Valve P0443 Surge voltage is monitored Surge voltage, Vps < Vb + 2V Battery voltage 10V Continuous

2 Drivingcycles

Purge Duty 100% and Intake air temp. > 5?Intake air temperature < 45? and Load value 25% ~ 70%P0453 Output voltage of tankpressure sensor is monitoredSensor output voltage > 3.5V Engine speed > 1440rpm

Purge Duty = 0% and Vehicle speed 29.75KPHP0452 Output voltage of tankpressure sensor is monitored Sensor output voltage < 1.0V

Continuous

>Meanvalue+P1 Vehicle speed < 2.5KPH

Fuel tankpressure sensor

P0451 (P1=pressure with full tank) Oscillation betweenmax. & min. voltage 4.9VP0462 < 1.0V

Fuel LevelSensor

P0460

Change in outputvoltage(VFLS) and output

voltage(VFLS) are monitored and VFLS1.0 4.6VTime after start > 2secFuel

temperaturesensor P0183 Rationality Check | Fuel temp. at start -water temp. at start | > 15?

Water temp atstart - air temp.

at start< 5?

Continuous 2 Drivingcycles


KLRN > +12.5% Idle

KI > +25% KLRN > +12.5%

P0171(Toolean)

A/F learning value(KLRN) &integral value of A/F

feedback compensation(KI)are monitored

Partload KI > + 15.2%

KLRN < -12.5% Idle

KI < -30% KLRN < -12.5% P0172(Too rich)



Partload KI < -10.9%

Closed loop


KLRN > +12.5% Idle

KI > +25% KLRN > +12.5% P0174(Too ean)



Partload KI > + 15.2%

KLRN < -12.5% Idle

KI < -30% KLRN < -12.5%

Fuel system(Bank 1)

P0175(Too rich)



Partload KI < -10.9%

Closed loop


Closed loop From lean to rich (TLR) > 1.1sec

Engine coolant > 35?Load value 25~60%

P0133

Response time from lean torich (TLR) & from rich to lean

(TRL) are monitored when A/Fis intentionally changed. From rich to lean (TRL) > 0.95sec Engine speed 1375~3000rpm

8secContinuous

2 Drivingcycles

Engine coolant > 77?

OxygenSensor

(Bank 1, front)

P0132 Circuit voltage(Vf) ismonitored.Circuit voltage after

applying 5V to sensor 4.5V Engine speed > 1200rpmLoad value > 25%

P0136 Circuit voltage(Vf) ismonitored.Circuit voltage after

applying 5V to sensor 4.5V Sensor voltage 70? Continuous 2 Drivingcycles


OxygenSensor

(Bank 1, rear)

P0139 Rationality Check Response Rate, TRL 1secFuel Cut on

3secContinuous

2 Drivingcycles


Closed loop From lean to rich (TLR) > 1.1sec Engine coolant > 35?

Load value 25~60%P0150

Response time from lean to rich (TLR) & from rich to lean

(TRL) are monitored whenA/F

is intentionally changed.From rich to lean

(TRL) > 0.95sec Engine speed 1375~3000rpm

8secContinuous

2 Drivingcycles


Oxygen Sensor(Bank 2, front)

P0152 Circuit voltage(Vf) ismonitored. Circuit voltage 4.5V Engine speed > 1200rpmLoad value > 25%

P0156 Circuit voltage(Vf) ismonitored. Circuit voltage 4.5V


Circuit voltage Vf 0.5VP0160

Circuit voltage is monitored when A/F is made to be rich

15% during 10sec Circuit voltage Vr < 0.1VEngine coolant > 70? Continuous 2 Drivingcycles


Oxygen Sensor(Bank 2, rear)

P0159 Rationality Check Response Rate, TRL 1sec Fuel Cut on3sec

Continuous2 Driving

cycles

P0135(front) < 200mA orOxygen SensorHeater (Bank 1) P0141(rear)

Heater circuit current(AH) ismonitored.

Circuit current, AH 3.5A Heater on Continuous

2 Drivingcycles

P0155(front) < 200mA orOxygen SensorHeater (Bank 2) P0161(rear)

Heater circuit current(AH) ismonitored.

Circuit current, AH 3.5A Heater on Continuous

2 Drivingcycles

< 0.2V or P0122 Output voltage is monitored. Output voltage, VTPS 2V Idle switch on

Load value < 30%P0123 Output voltage is monitored. Output voltage, VTPS > 4.6V Engine speed < 3000rpm

> Th1(rpm,load)

Throttle positionsensor

P0121 Rationality Check Output voltage, VTPS < Th2(rpm,load)Engine coolant > 81?


Cam positionsensor P0340

Change in output voltage(Vcam) is monitored. Vcam 0 Continuous

2 Drivingcycles

Change in output voltage(Vcrank) is monitored. Vcrank 0 Cranking switch onCrank angle

sensor P0335 Patterns of the signal combinations of the crank angle sensor signal& cam position sensor signal are monitored every 2sec continuously.



P0102 Output voltage is monitored. Output voltage, VAFS < 1.055V Engine speed > 3000rpmEngine speed 2000rpm

P0103 Output voltage is monitored. Output voltage, VAFS 4.5VTPS 2V

Output voltage, VAFS 0.957V ~1.055VVAFS 0.039V

Cranking switch on

> Th1(rpm,tps) Engine coolant > 81?

Air flow sensor

P0101 Rationality Check

Load value< Th2(rpm,tps) Intake air temp. 5 < AT < 45?


< 50 orP0115 Resistance of sensor(Rcts) ismonitored Resistance, Rcts 72k Time after start > 60sec Continuous

2 Drivingcycles

>300sec@-8? AFS voltage > 1.7V>110sec@20? Engine coolant -10?>60sec@82? Air temperature -10?>300sec@-8? AFS voltage 1.7V>200sec@20? Engine coolant -10?

P0125Time(Tfbi) from engine startingto the reaching engine coolant

temp. of F/B onTfbi

>60sec@82? Air temperature -10?

300secafter

enginestart

2 Drivingcycles

Time(Tdf) is monitored(elapsed time under 40?

after over 40? once)Tdf > 300sec

300sec

Continuous

Engine speed > 1500rpmLoad value > 25%

coolant at start > 7?

Coolanttemperature

sensor

P0116

Temperature shifting ismonitored | Wtmax - Wtmin | < 1?

Air temperature < 60?

300secContinuous

2 Drivingcycles

P0112 Resistance, Rats < 0.09kIntake airtemp. sensor P0113

Resistance of sensor(Rats) ismonitored Resistance, Rats 50k Time after start > 2sec Continuous

2 Drivingcycles

P0506 < Target-100rpm ISC Feedback onIdle speedcontrol P0507

Real engine speed & targetengine speed are monitored. Real engine speed >

Target+200rpm Engine coolant 77?Continuous 2 Drivingcycles


Idle switch P0510 Condition of idle switch ismonitored.

Idle switch is notmade "on" for at leastonce during 1 driving

cycle

Engine speed < 812rpm Continuous 2 Drivingcycles

P0201P0202P0203

Engine speed < 1000rpm

P0204P0205

Fuel injector

P0206

Surge voltage(Vinj) atinjector drive is monitored. Surge voltage, Vinj

< Vb + 2VVb : Battery V

TPS voltage < 1.16V


Engine coolant > 70?Engine speed 1400~3000rpm

Air fuel ratiofeedback(Bank 1)

P0134

O2 sensor staying time(TFB2)below or under the referencevoltage to decide rich/lean is

monitored.

Time, TFB2 > 15sec


15secContinuous

2 Drivingcycle

Engine coolant > 70?Engine speed 1400~3000rpm

Air fuel ratiofeedback(Bank 2)

P0154

O2 sensor staying time(TFB2)below or under the referencevoltage to decide rich/lean is

monitored.

Time, TFB2 > 15sec


15secContinuous

2 Drivingcycle

Engine speed > 2500rpmLoad value > 55%Power steeringpressure switch P1521

Signal of power steering pressureswitch is monitored.

P/S pressure switchsignal on

Engine coolant > 20?Continuous NoMIL ON

Engine coolant > 45?Intake air temp. > 5?P0106 < 0.1V or> 4.6V

Load value 30% ~ 55%P0108 > 4.2V Load value < 30%

Manifoldabsolute

pressure sensor

P0107

Output voltage(Vmap) ismonitored. Output voltage, Vmap

< 1.8V Load value > 70%


Time after start > 2secEngine speed 2500rpmKnock sensor P0325 Signal at current segment iscompared to previous one. Amount of change < 0.06V

Load value 30%Continuous NoMIL ON


Engine coolantat start 5? ~ 60?

Intake air temp.decrease after

start< 5?

Thermostat P0128

After given time (function ormass air flow, vehicle speed,engine speed) has elapsed,

engine coolant temperature ismonitored.

Engine coolanttemperature after given

time has elapsed.< 77?

Engine coolantat start - intake

air temp. at start< 10?

10~30min.dependingon mass airflow, vehicle

speed,enginespeed

2 Drivingcycles

Battery voltage 10VBattery backupline P0560

VB backup voltage ismonitored. VB backup voltage < 2V Duration 10sec

Continuous 1 Drivingcycle

Ignition coil P0350 Current through ignition coil ismonitored.

No current of 1 or 2 IGcoil group at the 3 IG

coil group

During48 ignitions Engine speed < 4000rpm Continuous

2 Drivingcycle

Ignition failuresensor P0320

Current through ignition coil ismonitored.

No current at the 3 IGcoil group

During32 ignitions Engine speed < 4000rpm Continuous

NoMIL ON

159Sirius 2.4 Eng.

Sirius2-Engine

160Sirius 2.4 Eng. - Contents

Contents- General Description

- Engine Feature

- Timing Belt

- Engine Tightening Torque

- ECM Overview

- ECM Input/Output

161Sirius 2.4 Eng. General Description Sirius2 EngineThe Sirius2 engine is In-line 4 Cylinder DOHC engine adopted aluminium oil pan, inlet type cooling system, DLI type ignition coil integrated Power Transistor, and a ignition failure sensor added to detect ignition problems to increase serviceability.

Also, hall type CKP and CMP sensors are installed. This engine incorporates only one timing belt.

The Sirius2 engine is designed by Mitsubishi Motor company and manufactured by Hyundai Motor Company.

Item Sirius 2.4 DOHC Capacity(cc) 2351 Engine type In line 4 cylinder MPI DOHC

Bore Stroke 86.5 100 Compression ratio 10:01

Max. Power(PS/RPM) 140/5500 Max. Torque(Kgm/RPM) 20.2/3000

Ignition Timing BTDC 5 2 Idle RPM 800 50RPM

Valve Clearance 0(HLA) Fuel Pressure(Kg/) 3.06

Ignition Order 1342

162Sirius 2.4 Eng. Engine Feature

Top View

Connectorfor CKP

ISA

Connector for IG Coil

PCSV

163Sirius 2.4 Eng. Timing Belt

Timing Belt

6~8 mm

2. INSTALL TIMING BELT

1. ALIGN TIMING MARKS

3. REMOVE SETG PIN

4. TURN THE CRANK-SHAFT SPROCKET2 REVOLUTION

5. CHECK THE CLEARANCEOF AUTO TENSIONER

CAMSHAFT SPROCKET

OIL PUMP SPROCKET

AUTO TENSIONER

CRANKSHAFTSPROCKET

164Sirius 2.4 Eng. Tightening Torque

Tightening Torque

CAMSHAFT BEARING CAP: 19~21Nm

CONNECTING ROD BEARING CAP BOLT: 18~22Nm + 90~94

MAIN BEARING CAP BOLT: 25Nm + 90~94

CYLINDER HEAD BOLT:OVERHAUL WITHOUT REPLACE:

20N.m + 90~94+ 90~94REPLACE GASKET:

80N.m, LOOSE, 20N.m + 90~94+ 90~94REPLACE HEAD BOLT:

20N.m + 180~184, LOOSE, 20N.m + 90~94+ 90~94

165Sirius 2.4 Eng. ECM overview ECM Overview

CKPKnock sensorECT

O2 sensor

ISA

MAP

Fuel PressureRegulator

PCSV

IG Coil

F/Pump

166Sirius 2.4 Eng. ECM Input/Output

ECM Input/Output

MAP

Oxygen sensor

CKP

CMP

ECT

IAT

Knock sensor

VSS

Various switches

Fuel control

Ignition control

Knocking control

Idle speed control

Purge control

Cooling fan control

A/C COMP.control

C/Relay control

Alt. current control

ECMMELCO

Presin del turbo a la salida del intercooler Temperatura del aire a la salida del intercooler

sorento motor

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